p.1 

OAR Box 1313 

Preppedby LaTeiaShed 

Document Number: 

62) ll-B-36 

Docket Number: 

A-88-02 

Printed 6/12/2008 9:03:30 AM Sheet 62 of 99 
P.2 

V 

MRI® A-88-02 

MIDWEST RESEARCH INSTITUT' 

IT-"£-3(4, Suite 3f: 

401 Hamson Oaks Boutevat 

Cnrv. NC. 275! 

Date: May 17, 1988 

Subject: Technical Review of the Production Rate Analyses by JACA 

Corporation 

Chromium Electroplating NESHAP 

EPA Contract 68-02-3817; ESD Project 85/02a _. „-—~-

MRI Project 7717-K [^"ZT R M T i?, \r 

yx ^:s.Lx.ssx.~- -*\ 

From: Robin Barker^" Z..7 !.; , 

; M ; -t- •••' .sy \y..y 

To: Andrew Smith 

ESD/ISB/SSS (MD-13) 

U. S. Environmental Protection Agency 

Research Triangle Park, N.C. 27711 

I. Purpose 

The purpose of this memorandum is to present the technical issues 

concerning individual process parameters used in the derivation of hard 

and decorative chromium plating model plant production rates for specified 

end products. Some of these issues were discussed with Mr. Wayne Morra of 

JACA Corporation (JACA) in a telephone conversation with Robin Barker of 

Midwest Research Institute (MRI) on May 4, 1988. The end-product 

parameters developed by JACA are used to determine the economic impacts 

presented in BID Chapter 8. These end-product parameters are presented in 

Attachment 1. The specific parameters in question are (1) plate 

thickness, (2) unit surface area of parts, and (3) the production rate 

assumptions. 

II. Plate Thickness 

The plate thicknesses developed by JACA and presented in BID 

Chapter 8 for faucets, sockets, ratchets, and automobile parts appear to 

be incorrect based on available information. The plate thickness given 

for these decorative chromium plated products are equal to or greater than 

1 thousandth of an inch (mil). The maximum plate thickness for decorative 

chromium applications is 1 mil. Most decorative chromium electroplaters 

included in the Section 114 data base and trip report data base plate 

parts with thicknesses ranging from 0.01 to 0.2 mils. 

Mr. Morra responded that a computer program (Attachment 2) was used 

to calculate the plate thickness or plating time depending on which 

variable was unknown for the given end product. Also, Mr. Morra stated 

that the plate thickness specified in mils was incorrect because a mil was 

interpreted as a millionth of an inch instead of a thousandth of an 

inch. When the correct conversion factor is applied to convert inches to 

mils, the plate thicknesses appear representative of plate thicknesses 

/ 
P.3 

applied in decorative chromium plating. To ensure that the means of 

calculating plate thickness is consistent between the BID chapters, MRI is 

providing the following equation for calculating plate thickness or 

plating time: 

Z = XY/518 (plate thickness) 

or 

Y = Z 518/X (plating time) 

where, 

X = current density in amperes/square foot (A/ft ) 

Y = plating time in hours (h) 

Z = plate thickness in mils 

518 = electrochemical equivalent at 10 percent cathode efficiency in 

A-h/rall-ft 

III. Unit Surface Area of Part 

The unit surface area developed by JACA and presented in BID 

Chapter 8 for industrial rolls and hydraulic cylinders appears 

inconsistent with information obtained through the Section 114 information 

requests and the test program. Data obtained during an emission test at 

Roll Technology, Inc., indicate that an average surface a^ea of an 

industria] roll is approximately 1,000 square inches (in. ) instead of the 

4,000 in. that JACA currently is using. Data obtained through 

Section 114 information requests from hard chromium plating plants 

indicate that typical syrface area values for a hydraulic cylinder range 

from 1,000 to 1,500 ic*. . The value given by JACA for a hydraulic 

cylinder is 271.4 in. . Therefore, MRI recommends that the unit surface 

area values given for these end products be revised as follows: 

2 

Unit surface area of an industrial roll = 1,000 in. 

Unit surface area of a hydraulic cylinder = 1,250 in. 

IV. Production Rates Assumptions 

The production rate assumptions developed by JACA and presented in 

BID Chapter 8 for each end-product are based on data obtained from 

plants. These data should not be used to characterize production rates of 

the model plants because: (1) the production rate for a given plant is 

directly proportional to the total working volume of the plant and would 

need to be adjusted to match the working volumes of the model plants and 

(2) it appears that some production assumptions obtained from plants was 

incorrectly interpreted. For example, one of the production rate 

assumptions for ratchets was that a rack holds 50 square feet of surface 

area. One rack of parts could not hold 50 square feet of surface area; 

however, the tank capacity in terms of part surface area may be 50 square 

feet. 

at-
P.4 

In the conversation with Mr. Morra, these concerns were presented 

and Mr. Morra stated that the production rate assumptions would be revised 

based on data derived by MRI on the production capacity for the individual 

model plants. These data are presented in Tables 1 and 2 for each hard 

and decorative chromium electroplating model plant, respectively. An 

example calculation for deriving the production rate in square footage per 

year and parts per year is presented in Attachment 3 for both a hard and 

decorative chromium plating model plant. Also, presented in Attachment 3 

are examples of how the information presented in Tables 1 and 2 should be 

used to characterize the model plant production rate in terms of rack 

populations or total tank capacities. 

The production rates for the model plants are inputs to a computer 

program which calculates plating costs. This program was developed by 

modifying the program presented in Attachment 4. Modifications were 

necessary since the program in Attachment 4 was written for barrel plating 

operations, a type of operation not used in the model plants. Proper 

documentation for these modifications will be needed for future reviews of 

drafts for BID Chapter 8. This documentation would enable reviewers to 

better assess whether this program is appropriate for calculating plating 

costs for specific operations. 

4 Attachments 
P.5 

TABLE 1. PRODUCTION RATE ASSUMPTIONS FOR 

HARD CHROMIUM PLATING OPERATIONS 

Production capacity, 

Plant size/tank size square feet of partsa 

Small model plant 

Model tank . 

1 <? (12.0,3.5,6.0)D 28 

Total 28 

Medium model plant 

Model tanks 

1 18 @ (4.0,4.0,10.0)J 

2 @ (12.0,4.0,6.0)° 2 @ 32 

1 @ (25.0,3.0,6.0)D _50 

Total 132 

Large model plant 

Model tanks . 

2 @ (4.0,4.0,10.0)? 2 e 18 

4 <? (12.0,4.0,6.0)° 4 <P 32 • 

2 § (25.0,3.0,6.0)D 2 @_50 

Total 264 

aSurface area of part-to-volume of tank ratio is 0.12 ft /ft . Production 

factor is based on maximum value from test data at hard chromium plating 

.facilities. 

Number of tanks in model plant and the length, width, and depth of each 

tank in feet. Tank freeboard space = 6 inches. 

f 
P.6 

TABLE 2. PRODUCTION RATE ASSUMPTIONS FOR DECORATIVE CHROMIUM 

PLATING OPERATIONS 

**" ' " ' "*" ' ' -^——-^ - _^_^_ _ ,., ., . . _ • ., , ... 'TM!—!— • - ———— — 

Plant size Production rate assumptions 

Smalla One rack of parts every 2 ft of tank length (i.e., six racks 

per tank) 

Mediuma One rack of parts every 2 ft of tank length (i.e., six racks 

per tank) 

Large One rack of parts every 6 ft of tank length (i.e., two racks 

per tank) 

aBased on data obtained from source test at Automatic Die Casting 

.Specialists, Inc. 

DBased on data obtained from source test at Delco Products Division, 

General Motor Corportion. Economic impacts for the large model plant 

should be based on bumper production only. 

\S 
P.7 

Attachment 1. 

End-Product Parameters Developed by JACA Corporation 
P.8 

FAUCETS 

Firms Contacted: 

Delta Faucets, Masco Corp. 

American Standard Inc. 

Stanadyne, Inc. 

Sterling Faucet Company 

Parametric Values of Selected Faucet 

Surface Area 

Current Density 

Plating Thickness 

Plating Time 

Production Assumptions 

Rack Holds 

Production Rate 

Labor Cost 

Overhead Factor 

Profit Factor 

Commission Factor 

88.5 sq. inc. 

60-75 amps/sq. ft 

10-20 mils 

4 mins. 

50 sq. ft. 

12 racks per hour 

$12 per hour 

2.5 

10% 

15% 

Unit Cost $.38 

7 
P.9 

HAND TOOLS 

Firms Contacted: 

SK Hand Tools Corp 

Stanley Works Inc. 

Snap-On Tools Corp 

Easco Corp. 

L.S. Starrett Inc. 

• 

• 

Vermont American Corp. 

Petersen Manufacturing Co., Inc. (Nickel) 

Parametric Values of Selected Hand Tools 

Surface Area 

Current Density 

Plating Thickness 

Plating Time 

Production Assumptions 

Rack Holds 

Production Rate 

Labor Cost 

Overhead Factor 

Profit Factor 

Commission Factor 

Unit Cost 

Socket 

3 sq. in. 

50 amps per 

sq. ft. 

1 mil 

4 mins. 

Socket 

50 sq. ft 

12 racks/hr. 

$12/hr. 

2.5 

10% 

15% 

$.013 

Rachet 

25 sq. 1n. 

60 amps per 

sq. ft. 

1 mil 

4 mins. 

Rachet 

50 sq. ft. 

12 racks/hr. 

$12/hr. 

2.5 

10% 

15% 

$.11 

Tape Measure 

14 sq. 1n. 

400 amps per 

sq. ft. 

.015 mils 

15 mins. 

Tape Measure 

50 sq. ft. 

3 racks/hr. 

$12/hr. 

2.5 

10% 

15% 

$.24 

/ 
AUTOMOBILE PARTS 

First Contacted: 

P.10 

Dura Plating 

General Motors Corp. 

American Motors Corp. 

Allied Finishing 

Motor Vehicles Manufacturers 

Assoc. 

Automotive Information Council 

Society of Automotive Engineers 

Motor and Equipment Manufacturers Association 

Chrysler Corp. 

Ford Motor Corp. 

Thompson Industries 

Bumper Recycling Association of 

North America 

National Assocation of Auto Trim 

Shops 

Motor Vehicle Manufacturers 

Association, Inc. 

Parametric Values of Selected Automobiles 

Surface Area 

Current Density 

Plating Thickness 

Plating Time 

ction Assumptions 

Rack Holds 

Production Rate 

Labor Cost 

Overhead Factor 

Profit Factor 

Commission Factor 

Electroplating Cost 

Decorative 

40 feet 

75 amps sq. ft. 

10-20 mils 

4 mins. 

Decorative 

50 sq. ft. 

12 racks per hr. 

$12/hr. 

2.5 

10% 

15% 

$25 

Hard 

8 feet 

288 amps sq. ft 

.001 inches 

2. noun s 

Hard 

60 sq. ft. 

1/2 rack per hr 

$12/h4. 

2.5 

10% 

15% 

$100.12 
P.11 

INDUSTRIAL ROLLS 

Firms Contacted: 

Chromium Industries, Inc. 

New Castle Industries 

Roll Technology Corp. 

Schmumacker Corp. 

Southern Plating Inc. 

Electrocoatlng Inc. 

Simmons Plating and Metal Finishing Co. 

Parametric Values of Selected Roll 

Surface Area 4,000 sq. 1n. 

Current Density 2 amps per sq. in. 

Plating Thickness .001 inches 

Plating Time 2 hours 

Production Assumptions 

Tank Holds One roll 

Production Rate 1/2 roll per hour 

Labor Cost $12 per hour 

Overhead Factor 2.5 

Profit Factor 10% 

Commission Factor 15% 

Cost per sq. in. $.10 

/<? 
P.12 

BACKHOES - HYDRAULIC CYLINDERS 

Firms Contacted: 

John Deere Co. 

Case, I. I. 

McKay Plating Co. 

Industrial Chrome, Inc. 

NAVISTAR (formerly International Havester) 

Parametric Values of Selected Backhoe-Hydraullc Cylinders 

Surface Area 

Current Density 

Plating Thickness 

Plating Time 

Production Assumptions 

Tank Holds 

Production Rate 

Labor Cost 

Overhead Factor 

Profit Factor 

Commission Factor 

Cost per sq. in. 

Cost per backhoe 

271.4 sq. 1n. 

2 amps sq. 1n. 

.001 Inches 

2 hours 

80 sq. ft. 

40 sq. ft. per hr. 

$12 

2.5 

10% 

15% 

$.065 

$17.7 

/ / 
P.13 

Attachment 2. 

Computer Program Used by JACA Corporation to 

Calculate Plate Thickness 

/ > 
P.M 

10 REM STORED AT FARADAY - A PROGRAM TO CALCULATE PLATING TIME OR THICKNESS 

20* REM 'BA33D OM TABLES FROH VARIOUS GUIDEBOOKS 

50 REM PROGRAMMED BY L.J.DURNEY NOVEMBER 1933 

40 CL3 

50 PRIMT T;u3(31);"This is FARADAY" 

55 PRINT TA:-3(i6);"a program to calculate Dlating thickness or time" 

SO PRIMT:PRINT TAB(39);"by" 

70 PRI'II: PRINT TA3( 31 ); "Lawrence J. Durney" 

50 PRIMT TA3(32);"November 20,1983" 

?0 FOR 1=1 TO 2000:NEXT I 

100 CLS 

110 PRINT:PRINT:PRINT 

120 PRIMT TAB(22);"The following options are available:" 

130 PRIMT:PRINT TAB(10);"1. Calculate plating time - area known" 

140 PRIMT 7AB(10);"2. Calculate plating time - area unknown - barrel work" 

130 PRIMT TABOO); "3. Calculate thickness - time - current - area known" 

1-30 PRIMT TAB(10);"4. Calculate weight of coating - time - current - area know 

170 PRIMT:?RINT TAB( 17);"Enter the number of the desired program" 

130 INPUT 1 

190 IF Z<1 OR Z>4 THEN PRINT "You have entered an invalid number. Try again.": 

TO 170 

200 OM Z GOTO 300,800,1900,1900 

300 REM - PLATING TIME - AREA KNOWN 

310 CLS 

320 PRINT:PRINT:PRINT 

330 PRIMT TAB(23);"PLATING TIME CALCULATION" 

340 PRIMT-.PRINT TAB(10); "It will estimate the proper plating time for any" 

550 PRIMT TA3(10);"thickness needed." 

560 PRINT:PRINT TAB(10);"You must know the required thickness," 

370 PRINT TA3(27);"the area of a part or rack load and" 

530 PRINT TA3(27);"the average current density needed for good plating." 

5?0 FOR 1=1 TO 5000:NEXT I 

100 CLS 

•110 PRINT: PRINT: PRIMT-

•£0 PRINT TA3(10) ; "V/hat metal is to be plated?" 

4 50 PRIMT TA3(10);"Enter full name in capital letters." 

440 INPUT 33 

•150 G0SU3 3200 'GET DATA 

460 PRINT:PRINT—"Enter the required thickness -i-n-inches e.g. .001 or .0002." 

470 INPUT T ...;.". 

430 PRINT:PRINT "Enter the surface area of the part or rack in square feet." 

490 PRINT "Do not use fractions. If necessary use decimals" 

500 INPUT 3 

510 PRINT:DRINT"Enter the average current density to be used." 

520 PRIMT "Enter as amps per square foot." 

550 INPUT ? 

540 R=3*P 

550 M=(T*1000)*D*50/P 

550 CLS 

570 PRIMT:PRINT TAB(10);"At 10055 efficiency, it will require ";M;" minutes" 

530 PRIMT T-\3(15);"to deposit a thickness of ";T;" inches." 

590 FRIMTtPRIMT TABOO); "It will require ";R;" amperes per part/rack." 

600 PRINT:PRIMT TAB(10);"You will have to adjust this time if" 

/S 
P.15 

610 

620 

as 

630' 

540 

550 

ooO 

570 

530 

590 

700 

710 

720 

730 

300 

310 

320 

330 

840 

850 

360 

370 

380 

900 

910 

915 

915 

920 

930 

940 

950 

•?60 

970 

930 

990 

1000 

1010 

1020 

1030 

1040 

1050 

1050 

1070 

1030 

1097 

1100 

1110 

1120 

1130 

1140 

1150 

1150 

1170 

1130 

1190 

1200 

you have other parts or racks 

solution? (Y or M)" 

to calculate" 

THEN GOTO 460 

"Do you have other solutions to calculate? (Y or N) 

PRINT TA3(15); "your solutioM is not 10055 efficient." 

PRINT:PRINT TAB(10);"To do this, divide the time by the efficiency express 

a decimal." 

'PRISIT: PRINT TAB(10);"Do 

PRINT TAB(15);"for this 

INPUT Z3 

IF Z3="Y" OR ZS="v" 

PRINT:PRINT TAB(10) 

INPUT Z3 

IF Z3="Y" OR ZS="y" THEN GOTO 400 

PRIMT:PRINT TA3(10);"Do you want to use one of the other options? (Y or N) 

INPUT ZS 

IF Z3="Y" OR Z$="y" THEN GOTO 100 

END 

REM - CALCULATE PLATING TIME - BARREL WORK 

REM - OR RACK WORK OF UNKNOWN AREA 

CLS 

PRINT: PRINT: PRINT -ZZ^i.jr----

PRINT TA3(23);"Plating time'calculation" 

PRINT:PRINr TAB(10);"It will estimate the proper 

PRINT TABOO) ; "thickness needed when the area is 

plating time for any 

n o t known. " 

PRINT TAB(10);"It may ba^xised fo r stamping s or barre l plate d parts. " 

"You must know: " 

"The "base metal to be plated" 

"The weight in ounces of a part or a number of parts" 

"or the average dimension and length." 

"of the pieces to be plated." 

"The average current density needed for good plating." 

1. stampings or 2. screw machine parts?" 

proper number":INPUT Z 

"Wrong entry. Try again. ":G0T0 960 

PRINT-.PRINT TABOO) 

PRINT:PRINT TAB(15) 

PRINT:PRINT TAB(15) 

PRINT:PRINT TAB(15) 

PRINT:PRINT TAB(15) 

PRINT:PRINT TAB(15) 

FOR 1=1 TO 5000:NEXT 

CLS 

PRINT:PRINT:PRINT 

PRINT TAB(IO);"Are parts 

PRINT TAB(15);"Enter the 

IF Z<1 OR Z>2 THEN PRINT 

IF Z=2 THEN GOTO 1500 

CLS 

PRINT TA8(10);"What is the base metal?" 

PRINT TA3(15);"1. Aluminum; 2. Steel; 3- Copper; 

PRINT:PRINT TAB(10);"Enter the proper number." 

INPUT Z 

IF Z<1 OR Z>4 THEN PRINTT^ron g entry . Try agai n 

IF Z = 1 THEN W=1.6 X . 

I? Z=2 THEN W=4.5 

IF Z=3 THEN W=5! 

IF Z=4 THEN W=4.8 

PRINT:PRINT TAB(10);"Enter the approximate thickness of the stock" 

PRINT TABOO); "in inches." 

PRINT TA3O.0);"Do not use fractions. Use decimals." 

INPUT T1 

PRIMT:?RINT TA3(10);"Enter the weight in ounces of the piece or pieces 

PRINT TAB(10);"Do not use fractions. Use decimals." 

INPUT '.71 

S1='.71/(T1*W) 

PRINT:PRINT "The area is ";S1;" square inches per piece/pieces." 

S=S1/144 

PRINT: PRINT TABOO); "V/hat meta l is to be plated? " 

.Brass 

":G0T0 1010 

7 

"f 
P.16 

1210 PRINT TABOO) ; "Enter full name in capital letters." 

1220 INPUT 3$ 

1230 GOS'J 3 3200 

12*0 ?RIMT:PRINT TAB(10);"Enter the required plate thickness in inches e.g. .0 

or .0002" 

I250 INPUT T 

1250 ?RIMT:PRINT TAB(10);"Enter the average current density to be used." 

1270 PRI IT TABOO); "Enter as amps per square foot." 

1230 INPUT P 

•:

 : "0 R-5*? 

1 )0 R1=R*16/W1 

•;'!0 ?RINT:PRINT TAB(10); "Plating will require ";R;" amperes per piece/pieces. 

1720 PRINT TABOO); "or ";R1;" amperes per pound of parts." 

1"50 M=(T*1000)*D*60/P 

!340 ?RINT:?RINT TAB(10);"At ";P;" amperes per square foot" 

1550 PRINT TAB(10); "and 100?* efficiency," 

1560 PRINT TABOO); "it will rpqnirp ";M;" minutes to deposit" 

1570 PRINT TABOO); "a thickness of ";T;" inches." 

1330 PRINT-PRINT TAB(10);"You will have to adjust this time if" 

1390 PRINT TAB(10) ; "your solution is not 1005? efficient." 

'400 PRINT:PRINT TA3(10);"To do this, divide the time by the efficiency" 

1410 PRINT TABOO) ; "expressed as a decimal." 

1420 ?RINT:PRINT TA3(10);"Do you have other parts to calculate" 

1430 PRIMT TABOO); "in this way? (Y or tl)" 

1440 INPUT Z3 

1450 IF Z$="Y" OR Z$=»y" THEN GOTO 960 

1450 GOTO 700 

1500 PRINT:PRINT "Enter the average dimensions of the piece as a decimal." 

1510 PRINT:PRINT"If the piece is round, enter the average diameter." 

1520 PRINT:PRINT "If the piece is square or hexagonal" 

1530 PRIMT "enter the width of one face." 

1540 ?RINT:PRINT "Is piece round, square or hexagonal? (R,S,H)":INPUT C$ 

"!550 PRINT: ?RINT"Enter dimension" : INPUT V/2 

1550 PRINT:PRINT "Enter length":INPUT L 

1570 I? 03="R" THEN.S1=W2*3.142*L 

•:?30 IF C3="3" THEN S1=W2*4*L 

1590 IF C3="H" THEN S1=W2*6*L 

1500 PRINT:PRINT "The area of each piece is ";S1;" square inches." 

1610 S=31/144 

1520 PRINT:PRINT "Enter the metal to be plated." 

1550 ?RINT:PRINT TAB(10);"Enter the full name in capital letters." 

1540 INPUT 33 

1545 GOSUB 3200 'GST DATA 

1550 PRINT:PRINT TAB(10);"Enter the required plate thickness in inches e.g. .00 

or .0002" 

1550 INPUT T 

1570 PRINT:PRINT TAB(10);"Enter the average'current density to be used." 

1630 PRINT TABOO) ; "Enter as amDS per square foot." 

1590 INPUT P 

1700 R=3*P 

1710 PRINT:?RINT TAB(10);"Plating will require ";R;» amps per piece." 

1720 M=(T*1000)*D*60/P 

1730 PRIMT:PRINT TAB(10);"At ";P;" amperes Der square foot" 

IMO PRINT:PRINT TAB(10);"and 1003 efficiencv," 

1750 ?Ri:!T:?RINT TAB(10);"it will require ";M;" minutes to deposit" 

1760 PRINT:PRINT TAB(10);"a thickness of ";T;" inches." 

1^70 PRIMT:PRIMT TAB(10);"You will have to adjust this time if" " ' 

r

730 PRI>-12 TA3(10): "your solution is not 1003 efficient. ~~ 

1790 PRIMT:PRINT TAB(10);"To do this, divide the time by the efficiency," 

JOO PRSIT TABOO); "expressed as a decimal.." 
P.17 

1310 PRIMT:PRIMT "Do.you have othe r part s t o calculate " 

1320 PRINT TAB(10);"i n thi s way?(Y or N) " 

13.50 INPUT ZS 

1340 I? "3="Y" OR Z$="y" THEN GOTO 1500 

13 = 0 SSZ 700 

19ZD SSI ELATING THICKNESS CALCULATION 

1910 ZZ 

1920 ZZ Z TA3(25); "Plating thickness or weight calculation" 

1930 ?r... IT: PRINT TABOO); "It will extimate the average thickness or coating " 

19-0 PRINT TA3(10);"weight for any set of plating conditions." 

1950 PRINT:PRINT TAB(10);"You must know:" 

1960 PRINT:PRINT TAB(15);"Plating time in minutes" 

1970 PRINT:PRINT TAB(15);"Average current density in amps/square foot" 

1930 ?RINr:?RINT TAB(15);"What metal is being plated." 

1990 PRINT:?RINT TAB(10);"Enter full name of metal in capital letters." 

2000 INPUT 33 

20IO G0SU3 3200 'GET DAT7T-i-

4SiS 

2020 ?RINT:?R:M T TAB(10);"Ente r th e platin g time i n minutes " 

2030 INPUT I 

2040 PRINT:PRINT TAB(10);"Enter the current density in ASF" 

20 45 I :?UT ? 

2050 T=((M/60)*(P/D)/1000) 

2060 PRINT:PRINT "Under the conditions given, the thickness will be "; 

2065 PRINT USING ".######»• ;T; 

2055 PRINT " inches." 

2070 v/5 = T*3*1000 

2030 PRIMT:PRINT "A coating of "; 

2031 PRINT USING ".######»» ;T; 

2032 PRINT " inches will weigh "; V/3;" ounces per square foot." 

2090 PRINT .-PRINT "These figures are based on 1003 efficiency." 

2100 ?RINT:PRINT "If your solution is not 1003 efficient," 

2110 PRINT TA3(10);"they will have to be adjusted." 

2123 PRINT:PRINT "To do this, multiply by the efficiency," 

2150 PRIMT "expressed as a decimal." 

2140 PRINT:PRINT TAB(10);"Do you have more calculations" 

2150 PRIMT T;.3(10);"of this kind to do? (Y or II)" 

2160 INPUT 13 

•2170 • I ? :3=".' " OR Z$="y" THEM GOTO 1980 

Z130 ;)T0 70 : 

5200 RTM PR0J-RAM TO GET DATA— 

5 2''0 READ A3 . 3 C D ---'-

5220 IF A3="?399" GOTO 8270 

3230 IF AS=E3 THEN GOTO 8250 

3240 GOTO 3210 

3250 RESTORE 

3250 RETURN 

32T0 PRIMT TA3(10);"You have made an imorooer entry." 

3230 PRINT TA3(10);"We cannot find the needed data." 

3 2 90 PRINT ?A3(10);"We will print the entire list so you can" 

3500 PRUIT TA3(10);"see how to make the entry properly." 

35:0 ?R:;T:?RIN T TABOO) ; "If the metal you want is not on the list," 

35 20 PRINT TA3(10);"we cannot help you." 

Z

::"0 P'TMT i;3(10);'Tn that case, type STOP to end the program." 

J;-"-0 -y~. 1 = 1 TO 3000: NEXT I 

rzo :LS 

Sr 0 RZ5TOR3 

Z5 3 SPD A3,3,C,D ,{ 7 

)

:5j0 IF 43="9999" THEN GOTO 3420 •-? 

J400 PRINT Tn3(20);"AS " ' 

IP 
P.18 

sLL^ PfStir. 

.34 jO FRZIT TAB(20) j^-'AS 

-TfT~j;:3 3 533 " 

•120 PRINT "Enter STOP or the desire d metal exactl y as shown in the lis t above' 

TZ.'.-MT 35 

•:;d Z? 53<>"ST0P" THEN REST0RE:G0T0 8200 

-:10 PRIST T\B(10);"Sorry. You can add the needed data to the " 

SSI PRZ.T TABOO); "end of the data list to expand the program." :END 

ZliD 0,-ZA ANTIMONY,.56, .0018,10.4 

•470 DATA ARSENIC,.47,.00213,14.4 

043O DATA CADMIUM,.71,.00139,9.73 

"Z90 DATA CHROMIUM, . 59 ,. 00169 ,51 .3 

3 500 DATA CO SALT(OUS),.74,.00135,19.0 

:510 DATA COPPER(CYANIDE),.74,.00134,8.89 

?520 DATA 00PPSR(ACID),.74,.OO134,17.8 

i5"D DATA GCLD(+1),1.47,.00063,5.2 

55 10 DATA GOLD(+5),1.47,.00068,13.6 

•530 DATA INDIUM,.56,.00182,12.0 

•560 DATA IRON(+2),.65,-00153,17.9 

:3T0 DATA LEAD,.94,.00106,6.9 

350 DATA NICKEL,.74,.00135,19.0 \H° 

590 DATA PALLADIUM,.36,.00115,13.5 

• 500 D ATA P L ATINUM,1.60,.00062,27.3 

•510 DATA RHODIUM,. 95,. 00106,22.9 / •' . 

•520 DATA SILVER,.79,.00126,5.2 

7530 DATA TIN(+2),.61,.00164,7.8 

-.570 DATA TIN(h4),.61 ,.00164,15.6 $** 

3 550 DATA ZINC,.59,-00163,14.3 *^' 

55 50 DATA 9999 

5:00 REN LIST OF'VARIABLES 

••010 REM A3 - PLATING SOLUTION IN FILE 

Z'2D REM 3 - WEIGHT OF 0.001"-IM FILE* 

•}3 0 ?X.-\ C - THICKNESS OF 1 OZ IN FILE 

•MO REM D - AMO HOURS FOR 0.001" PER SQ FT IN FILE' 

O?0 RI ! 01 - INPUT DIMENSION FOR BAR STOCK 

- >30 ?.£'•! Z - TEMPORARY VARIABLE FOR NUMERIC INPUT 

.

:J7 0 RIM Z3 - DITTO ALPHANUMERIC INPUT 

; T-30 RIM 33 - INPUT PLATING SOLUTION USED 

-090 RIM Cl - INPUT SHAPE OF BAR STOCK 

.••'.OO RIM T - INPUT REQUIRED THICKNESS OR OUTPUT PROGRAM CALCULATED THICKNESS 

•'10 RI.-! T1 - INPUT STOCK THICKNESS - STAMPINGS 

•

120 RIM S - SURFACE AREA IN SQ FT - INPUT OR CALCULATED 

9130 RIM 31 - SURFACE AREA IN SQ INCHES' 

."•140 RIM ? - AVERAGE CURRENT DENSITY - INPUT OR CALCULATED 

-•50 RIM R - AMPERES REQUIRED PER RACK OR PER PART 

->3T) RIM R1 - DITTO PER POUND 

•i-70 RIM 1 - PLATING TIME IN MINUTES INPUT OR CALCULATED 

}'S RIM .7 - DENSITY OF SHEET METAL IN OZ/CUBIC INCH 

"S O RIM '.71 - WEIGHT OF PIECE OR PISCES INPUT 

37. 0 REM V/2 - DIMENSION OF BAR STOCK INPUT 

9. ' ) RIM '.75 - WEIGHT OF PLATED METAL CALCULATED 

9..0 RIM L - LENGTH OF PART - BAR STOCK OR CREW MACHINE 

9'Z'D IND 

/ / 
P.19 

Attachment 3. 

Example Calculations Provided by MRI 

S 
P.20 

EXAMPLE OF PRODUCTION RATE CALCULATIONS FOR 

HARD CHROMIUM PLATING APPLICATIONS 

Medium model plant parameters 

Ampere-hours per year = 42x10 

Model tanks = 1 @ (4.0,4.0,10.0) 

2 @ (12.0,4.0,6.0) 

1 @ (25.0,3.0,6.0) 

Operating time = 3,500 hours/year 

Percent time electrodes energized = 70 

Parameter values for hydraulic cylinders (Attachment 1) 

Current density = 288 amperes per square foqt 

Plating time at current density of 288 A/ft = 2 hours 

Plate thickness = 1 mil 2 

Surface area of hydraulic cylinder = 8.7 ft = 1,250 in * 

Ampere-hour requirements per square foot 

(288 A/ft2)(2.0 h) = 576 A«h/ft2 

Medium model plant production rate 

(42xl06 A«h/yr)(ft2/576 A»h) = 72,900 ft2/yr 

(72,900 ft2/yr)(part/8.7 ft2) = 8,380 parts/yr 

Production rate assumptions (Table 1) 

Maximum tank capacities for medium model plant 

(4.0,4.0,10.0) tank holds 18 ft or 2 cylinders 

2 tanks @ (12.0,4.0,6.0) hold 32 ft or.3 cylinders 

(25.0,3.0,6.0) tank holds 50 ft or 5 cylinder 

Maximum capacity for all tanks = 13 cylinders/2 h = 6.5 cylinders/h 

Production rate per hour 

[8,380 cylinders/yrl[(3i500 h/ ^ r)(o>7o) ] = 3.4 cylinders/h 

Therefore, maximum capacity is not exceeded and production rate of 

3.4 cylinders/h should be used. In the event that an end-product 

production rate is higher than the maximum capacity values of the plating 

tanks, then the production rate should be based on the maximum total tank 

capacity. 

•Based on Section 114 data. 

il 
P.21 

EXAMPLE OF PRODUCTION RATE CALCULATIONS FOR DECORATIVE 

CHROMIUM PLATING APPLICATIONS 

Medium model plant parameters 

Ampere-hours per year = 12.0x10° 

Model tanks = 2 @ (12.0,3.5,6.0) 

Operating time = 4,000 h/yr 

Percent time electrodes energized = 60 percent 

Parameter values for ratchets (Attachment 1) 

Current density = 60 amperes per square foqt 

Plating time at current density of 60 A/ft = 4 minutes = 0.067 h 

Plating thickness = 10-20 mils?* 

Surface area of faucet = 25 square inches 

Calculation of plate thickness for ratchets 

Electrochemical equivalent 518 ... 

assuming cathode efficiency = 2 

of 10 percent mil-ft 

( ^i8_^h ) ( ^t! K ^ ^ ) m 12Q9 Bir i „ 0#00 8 mi l 

mil-ft

 ou M UUb/ n plate thickness 

Ampere-hours requirement per square foot 

Medium model plant production rate 

(12.0xl06 Mj^ft^ ) = 3.0XIO6 ft2/yr 

2 

(3.0xl06 ft2/yr)( Pa rt )(1 4 4 ] n - ) = I7.0xl06 rachets/yr 

25 in. ft 

*Note: The plate thickness appears to be incorrect. 

X/o 
P.22 

Production rate assumptions 

Number of racks per hour for one tank 

Model tank is 12 feet long 

Table 2 data - 1 rack every 2 feet of tank length 

Therefore, 

(12 ft)(l rack/2 ft) = 6 racks in tank at one time or 6 plating cells 

per tank 

Plating time = 4 minutes 

4 min/6 cells = 0.67 min or 40 seconds/cell 

I.e., a rack is removed from the tank every 40 seconds 

Therefore, 

(1 rack/40 s)(60 s/1 min)(60 min/1 h) = 90 racks/h from one tank 

Medium model plant has two identical tanks 

Therefore, 

(90 racks/h/tank)(2 tanks) = 180 racks/h 

Square footage per rack 

[3.0xl06 ftVyr][(4,000^(0.60)1 =

 l'2S0 ft'/h 

plant % time 

operating electrodes 

time energized 

(1,250 ft2/h)(l h/180 rack) = 7.0 ft2/rack 

J/ 
P.23 

Attachment 4. 

Computer Program Used by JACA Corporation to 

Determine Unit Plating Costs 

J*-
By LAWRENCE J, 

Consultant 

There are three basic systems. Here's how they work and here's a 

computer program that lets you use your computer to do the 

calculations... 

DURNEY 

A successful cost-calculating procedure, like any accounting procedure, 

depends upon careful attention to a 

multitude of details. At the heart of 

any such calculation is the need for 

accurate knowledge of various operating costs. Therefore a casual approach to handling, recording and allocating expenditures is not only 

inexcusable, it is self destructive. 

There are three basic cost-calculating systems: 

The simplest system requires that 

you separate labor and its associated 

costs—vacation pay, hospitalization, 

social security payments and so on— 

from all other costs. This information is then translated into hourly labor costs for various labor categories, such as rackcrs', machine 

operators, packers and so on. 

Using this system, the shop manager determines the hours of various 

kinds of labor required for a given 

job anH divides by the number of 

parts or pounds plated to find his 

cost. This figure is multiplied by an 

overhead percentage to establish the 

cost of overhead for this particular 

job. Then these two costs are added 

to determine total processing cost. 

The total processing cost is then 

multiplied by a factor that takes into 

account expected profit plus a salesman's commission, if one is paid, to 

obtain a selling price. The factor (F) 

is: 

F=l(l-P-C) 

where P is the expected profit percentage and C is the commission 

paid, both expressed as decimals, 

(e.g., 10 pct expected profit is 0.10). 

This system works well for a shop 

that is very limited in scope and variety, e.g., a shop doing only barrel 

zinc plating. 

A more complex shop would require additional calculations to account for the varying costs of metals. 

This would be necessary in a shop 

plating copper, nickel, chromium and 

gold, for example. 

When this is the case, the shop 

manager must not only separate his 

labor costs, but must separate the 

costs of anodes and plating salts from 

all other costs. The overhead is again 

calculated, as previously. (Overhead 

will now be a lower percentage than 

in the first system, since metal cost 

is not included with overhead). 

PRODUCT; FINISHING 79 

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